Textile Enterprises Reduce Costs And Find A Way Out For Intelligent Manufacturing

In 2015, China spun

Exports to the EU fell by 9.3% over the same period last year, to 11.6% in Japan, and 2 times more than in 2008, and the outflow of orders was obvious.

The year of monkey has entered spring, and the cold winter of textile industry has not yet passed.

Last year, China's textile and clothing exports decreased by 4.9%, the first negative growth in the past 6 years.

In the first two months of this year, export declines continued to expand, garment exports dropped by 11.8%, and textile exports dropped by 9.3%.

As the largest textile country in the world, the comparative advantage of China's textile industry has always been obvious.

The complete industrial chain, lower labor costs, and cost-effective products and services make China's textile industry account for 54% of the world's total fiber processing, and textile and garment exports account for 37% of the world's total.

However, in recent years, the survival environment of China's textile industry has become increasingly difficult.

Labor costs continue to rise, reducing labor intensive enterprises.

Cost performance.

"Compared with 2008, the labor cost of enterprises has increased by 2.5 times, and the continuous increase of labor costs is the main pressure facing the textile manufacturing sector."

Huang Zuqun, chairman of China's Group Co., Ltd., introduces that labor cost accounts for 18% of the cost of the enterprise, which is the difficulty for enterprises to reduce costs.

The Japanese yen and euro continued to depreciate and tariff barriers increased, which led to the outflow of Chinese orders in the global market downturn.

In particular, the US led p Pacific Partnership Agreement (TPP) was signed before the Spring Festival this year, pferring large quantities of textile orders to Southeast Asia, especially Vietnam.

According to reports, after the implementation of TPP, Vietnam's tariff on textile exports to the United States will drop from 17% to 32% to 0.

"Relying on the efforts of the enterprises, the cost can be reduced by three to five percentage points, but the tariff is more than ten points, even high-quality enterprises such as the sun are also very difficult to digest."

Chen Lifen, chairman of Jiangsu sunshine group, said.

The outflow of orders is not only in the low-end sector, but also in the high-end market.

As the largest worsted spinning enterprise in the country, half of the products of Jiangsu sunshine group are exported to Europe and the United States.

However, since last year, Chen Lifen has found that many large and high-end customers have placed their orders back to Europe, because the European manufacturing costs of high-end products are already lower than those of China.

Customs statistics also verify the outflow of orders.

In 2015, China's textile and clothing exports to the EU decreased by 9.3% compared with the same period last year, and the volume of exports to Japan dropped by 11.6% over the same period last year.

Factor prices are rising and institutional costs have not been reduced.

For a long time, the high value-added tax of cotton spinning enterprises has resulted in the cost pressure of 4 percentage points.

Although the 9 provinces have launched a pilot reform in the past year, the lint used by cotton spinning enterprises can be deducted according to the applicable tariff rate of 17%, but due to the cumbersome formalities, the financial pressure of enterprises still exists.

In addition, the existence of cotton quotas still hamper the flexibility of the international market to stabilize costs and increase the operational difficulties of the cotton textile industry.

In 2015, the export volume of China's cotton textiles and clothing decreased by 9.7% compared to the same period last year, 5.6 percentage points higher than the 2014 decline.

"The import policy of cotton has not changed, and the interests of domestic cotton farmers and textile enterprises have been damaged."

Qiu Yafu, chairman of Shandong Ruyi science and Technology Group Co., Ltd., revealed that because of the impediment to the import quota of cotton, the high-quality cotton planted in Australia can only be sent to India to spin, and then imported to China to make fabrics.

"Now that India and Pakistan are catching up, they are selling their cotton yarn crazy."

Reduce costs and find a way out for intelligent manufacturing

Intelligent manufacturing can double the production efficiency. Enterprises hope to use intelligent technology to hedge labor costs. The fact that "people spend less and earn more" will become an unavoidable fact in the textile industry.

In early spring, China's first intelligent Knitting Industrial Park broke ground in Shuyang, Jiangsu.

Huang Zuqun placed high hopes on the new industrial park, which covers an area of 6000 mu.

"Labor cost is too high, it is difficult to press down, but the quality of workers is not high, the quality of products is very difficult to mention, this knot can only be solved by intelligent manufacturing."

Huang Zuqun said that by this intelligent pformation, the per capita output value of enterprises is expected to double.

Gao Baolin, chairman of the largest Hosiery Industry in Asia and chairman of Shanghai Zhong Hao group, is also optimistic about the promotion of intelligent manufacturing for the pformation and upgrading of the textile industry.

The start of the intelligent Knitting Industrial Park signed a 500 million yuan investment agreement on the same day.

"Investment in intelligent manufacturing is mainly to reduce costs and improve efficiency.

The less the people use, the more they make, which is the fact that the textile industry can't avoid. "

Intelligent manufacturing, located in "China made 2025", is positioned as the main direction of Chinese manufacturing. It refers to the intelligent activities in the manufacturing process through the man-machine integration system, so as to upgrade the traditional manufacturing system to the level of flexibility, intelligence and high integration.

This also means that China's manufacturing will have a more precise and agile manufacturing capability.

"If Ford's assembly line production mode supports mass production in the United States, and the way of production of Japanese TOYOTA makes the lean production ring the world, then the new mode of production that all countries are wrestling with is intelligent production.

Whoever grasps this data driven mode of production is likely to stand at the commanding heights of the new round of competition.

Wang Xiaoming, director of the first research room of the Ministry of industry and Economic Research of the State Council Development Research Center, said.

In fact, intelligent technology has great potential in pforming traditional industries, and some enterprises have begun to try out the intelligence of some manufacturing links.

In the Bong yarn production workshop in Bang yuan, Jiangsu, more than 300 machines are spinning rapidly, but it is hard to see the shape of the workers.

According to the relevant person in charge of the workshop, benefiting from the pformation of intelligent equipment investment and technological process, the workshop of seventy or eighty people was originally needed. At present, only 30 workers are on duty. Not only the production efficiency is greatly improved, but also the stability of product quality is higher.

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Intelligent manufacturing, uncertain factors perplexing Enterprises

Based on big data, the investment of intelligent manufacturing is billion yuan, and the risk of "eating crab" is not small.

Smart manufacturing makes people surprise and brings new challenges.

Intelligent manufacturing is not the intellectualization of manufacturing links. Those "eating crab" enterprises feel the data driving is forcing the textile industry to subvert the traditional pattern of "two skins" in manufacturing and marketing.

Intelligent manufacturing is breaking the line of production of "big order big manufacturing", and quicker catching and meeting the new demand of the Internet era of multi variety, small batch and fast delivery.

"We need to develop new industrialization and informationalization. What we lack is not technology, capital, nor human and experience, but imagination.

From the recent war of man and machine in the go world, intelligent development has provided us with unlimited space for future industrial development.

Zhang Xinhong, director of the information research department of the National Information Center, said.

In fact, intelligent manufacturing is making Chinese textile industry's original dare not think of things become reality.

At present, China's cashmere and T-shirt manufacturing can be automatically programmed by computer programming, and the knitting machine is formed at one time.

Consumers only need to select the color, thickness and function of the yarn through the Internet interface, as well as the function and pattern of the garment, and conduct online measurement.

"A man's shirt, you can choose 80 kinds of functions, such as quick drying, bacteriostatic and deodorant, and like your collar, sleeve, bag, button type, submit your volume data, from design to delivery as long as 6 days.

This is something I didn't dare to think about.

Yao Mu, academician of the Chinese Academy of engineering, said that at present, China's "intelligent manufacturing" has been able to design a customized suit for only 27 minutes.

"Such" made in China "is the implementation of supply side structural reform, which can meet the new needs of personalized services.

Although intelligent manufacturing has portrayed broad prospects for traditional industries, large enterprises such as GE and IBM have increased investment in artificial intelligence. But many people think that intelligent manufacturing is still in the stage of technology development, and even the basic concepts have not reached a consensus. It is understandable for enterprises to do some technical pformation.

People doubt that textile intelligence is a big gamble.

On the one hand, many entrepreneurs believe that machine replacement is not intelligent manufacturing. Intelligent manufacturing refers to the whole industry chain reengineering that covers procurement, design, manufacturing, packaging, logistics, finance, sales and management. It is based on the accurate calculation and judgment of big data instead of human brain decision making, so as to enhance the total factor productivity of the whole society.

Although smart manufacturing based on big data is in the stage of conceptual exploration, investment is calculated at 100 million yuan. Such disruptive pformation is like "crossing the river by feeling the stones", which is too risky.

On the other hand, even if the intelligence level of the manufacturing sector is improved, it is not known whether the investment of machine substitution is worthwhile for the textile industry.

Compared with automobile, machinery, electrical appliances and other industries, the output value of textile industry is relatively low. Large scale machine substitution can reduce labor cost, but the cost of machine investment, maintenance, upgrading and so on is not low.

Not only are enterprises confused, but also many local governments are worried about the way of textile intellectualization.

As a labor-intensive industry, the textile industry has long been a local livelihood industry to solve the problem of employment.

On the one hand, intellectualization can stimulate local investment and promote industrial upgrading. On the other hand, it means that a large number of workers may lose their jobs.

In Wang Xiaoming's view, the investment in intelligent manufacturing is very large, and investment risk may slow down or even hinder the pformation and upgrading of enterprises. Therefore, the government needs to invest more in the development of generic technology, so as to reduce the investment risk of technological pformation.

"At the government level, we should encourage trial and error through pilot projects.

Enterprises must also identify their own position. Before doing intelligent manufacturing, we must do well in basic skills such as lean production and digital management. We should start with the digital supply chain in the procurement link, the mobile robots in manufacturing links, and so on.

Wang Xiaoming said.